FORMED PIECE PARTICULARLY FOR USE AS PACKING MATERIAL, METHOD AND APPARATUS FOR ITS MANUFACTURE AND USE

Abstract: The invention relates to a form piece, particularly for use as a packing material. The form piece comprises a first outer surface (10) and a second outer surface (20). The first outer surface is made wrinkled and twisted. The second outer surfaces (20) functionning as the ends of the form piece (M) consist of sheet material layers forming the form piece (M), an air gap (IR) being between the layers. The invention relates also to a method and an apparatus for manufacturing the form piece, as well as to the use of the form piece.

Description: Formed piece particularly for use as packing material, method and apparatus for its manufacture and use The invention relates to a formed piece according to the preamble of claim 1, particularly for use as packing material. As to prior art, reference is made generally to the publications US-4, 237,776, US-3 ,799, 039, US-3,509,798 and WO 92/05948, from which a formed piece substantial¬ ly according to the preamble of claim 1 is known. Ac¬ cording to techniques disclosed in these publications, it is possible to manufacture packing materials of plate form. As to prior art, reference is also made to form pieces manufactured of cellular polystyrene which are commonly used as packing material in transport and storage of products e.g. in industry and trade, such as mail¬ order business. Form pieces made of cellular poly¬ styrene are light-weight, flexible and easy to use. They are cheap to manufacture on industrial scale, because a relatively cheap series mould can be used. Also, most form pieces can be recycled. As a counter¬ balance to the advantages presented above, however, there are a number of disadvantages. Form pieces of cellular polystyrene charge static electricity, for which reason their use is not recommended in certain applications; in addition, static electricity makes it more difficult to handle the form pieces. Cellular polystyrene is an oil-based material which, after the cycle of consumption of the form pieces, burdens dumping grounds. In other words, the disposal of the form pieces is an environmental problem. It should further be noted that the manufacture is relatively energy-consuming. The purpose of this invention is to present a new form piece for use as packing material, whereby a great deal of the above-mentioned problems can be removed by using the form piece of the invention, thus improving the state of art. For achieving these aims, the form piece of the invention is primarily characterized ' in that - a first outer surface forms a surface of a substan- tially cylindrical type, and that the sheet material is twisted in random order inside the form piece so that an air gap is provided between at least some sheet material layers or the like, for at least part of the length of the form pieces. A form piece arranged in the above-mentioned manner is thus manufactured of a sheet material, which in this context means particularly decomposable sheet materials, such as paper and/or plastic polymer materials manufactured and/or treated so that they are decomposable. As particularly cellulose-based mate¬ rials, recycled and/or waste paper can be used. Par- ticularly cellulose-based sheet materials, i.e. those manufactured of paper, are advantageous because they can be recycled by waste paper collection or disposed of by burning or composting. Form pieces of particu¬ larly cellulose-based materials do not charge static electricity, so they are easier to use in this respect than form pieces made of cellular polystyrene. Using suitably chosen cellulose-based materials, a form piece according to the invention competes very well in price and functional properties (price/quality ratio) with form pieces of cellular polystyrene currently in use. When form pieces according to the invention are used as packing material, the surface, wrinkled or treated by working the sheet material in a corresponding manner, induces good internal friction in the packing material and even partial mechanical adhesion of form pieces to each other, whereby a product packed by the packing material is kept in position during transporta¬ tion and storage and does not displace the packing material and sink to the bottom of the package space which might cause a risk of damaging the product, the outer surface of the product being in direct contact with the inner surface of the package without a protective zone provided by the packing material. Some advantageous embodiments of the form piece are presented in the other, dependent claims on the form piece. The invention relates also to a method, according to the preamble of the independent claim on the method, for manufacturing form pieces, particularly for use as packing material, on an industrial scale. The method of the invention is primarily characterized in that a bar-like blank is twisted around its longitudinal axis before cutting it into form pieces (M) of certain length. By the technical stages of the method presented above, it is possible to manufacture form pieces on an in- dustrial scale by continuous production, naturally within limits determined by the length of the con¬ tinuous web. Particularly reducing the width of the web or the like, i.e. the dimension transverse to its running direction, causes placement of the sheet ma- terial or the like in the cross-sectional area of the bar-like blank in random order so that in at least part of the cross-section, air gaps are left between the sheet material layers, providing the properties of flexibility of the form piece. By rotating the bar-like blank around its longitudinal axis, it is possible firstly to adjust the flexibility and second¬ ly to secure the coherence of the form piece after cutting the twisted bar-like blank. In addition to the flexibility or porosity of the form piece, the weight of the form piece can be adjusted by twisting. Some advantageous embodiments of the method are also presented in the appended dependent claims on the method. Further, the invention relates to an apparatus for manufacturing form pieces to be used particularly as packing material. The main characteristic features of the apparatus are presented in the characterising part of the independent claim on the apparatus. The invention relates also to the use of the form piece as packing material. In the following description, the invention will be described in more detail with reference to the appended drawing. In the drawing, Fig. 1 shows a schematic side view of an embodi¬ ment of the technical stages of the method for manufacturing form pieces of the inven¬ tion on industrial scale and Fig. 2 shows a perspective view of a form piece of the invention, manufactured by the method as shown in Fig. 1. In reference to Fig. 1, at least one cellulose-based sheet material R, such as paper, particularly recycled and/or waste paper, is arranged on a roll 1 at the starting end of the production line. Unrolling takes place from the roll 1 to a preformation unit 2, where the width of the web or the like is reduced in direc¬ tion perpendicular to the running direction of the web in order to produce a bar-like blank 3 , whereby the material of the web R is placed in the cross- sectional area of the bar-like blank. The preformation unit 2 can be e.g. a conical sleeve tapering in the running direction of the web, through which the web is guided to taper into a bar-like blank. Next in the production line are friction rollers 4 or corresponding arresting means which prevent the transfer of the twisting of the bar-like blank, which takes place after the friction rollers 4, past the friction rollers 4 in the incoming direction of the web. The friction rollers 4 can bo replaced (or supplemented) by arresting means in t oreformation mit 2, preventing the transfer of t twisting of zhe bar-like blank 3. Further in the production line, a twisting and drawing unit 5 for the bar-like blank 3 is provided at a dis¬ tance from the friction rollers 4, whereby the bar¬ like blank is twisted around its longitudinal direc- tion, the cross-sectional area of the bar-like blank being thus reduced in most practical embodiments. Having passed the twisting and drawing unit 5, the bar-like blank is cut into form pieces M by a cutting unit 6. At least one roll 1 is placed in an unrolling device which most usually does not require particular drive means but possibly only a friction brake. The pre- formation unit 2 is mounted to be stationary in connection with the production line but to be easily changeable according to the width and/or quality of sheet material of the web, such as paper. The friction rollers 4 are preferably provided with a control device for the pressure on the bar-like blank 3 to prevent twisting after the friction rollers 4 in the incoming direction. Using the twisting and drawing unit 5, the desired twisting with the desired tension can be achieved in the bar-like blank 3. The twisting and drawing unit 5 comprises in the first place means for directing the pressure required on the bar-like blank 3 for accomplishing the force for twisting, i.e. the friction force onto the surface of the bar¬ like blank 3, in the second place means for rotating the twisting and drawing unit 5 around the longitudinal axis of the bar-like blank 3 to produce the actual twisting, and in the third place means for drawing the bar-like blank 3 from the roll 1 and to feeding it to the cutting unit 6 at the next stage. The operational sequence of the cutting unit 6 can be adjusted by valve control at will. Figure 2 shows particularly a form piece produced by the method of Fig. 1, comprising a first outer sur¬ face 10 in the longitudinal direction of the form piece, the sheet material or the like of the form piece being in random order in a wrinkled or cor- responding spiral form KR. The first outer surface 10 forms a cylindrical surface, naturally within the framework of the random nature of the form of said surface. The ends of the first outer surface 10 are joined by second outer surfaces 20 in the cross- sectional direction of the form piece, where the sheet material or the like forming the form piece is randomly arranged in layers so that an air gap IR is provided between at least some sheet material layers or the like. By adjusting the tension of the twist- ing of the bar-like blank, the number and size of air gaps can be changed and thus the flexibility and porosity properties of the form piece can be adjusted. The sheet material is twisted in random order inside the form piece so that there is an air gap between at least some sheet material layers or the like on at least part of the length of the form piece, i.e. in the direction between the second outer surfaces. The surfaces of the form piece, in the longitudinal direction on one hand and in the cross-sectional direction on the other hand, are advantageously essentially perpendicular to each other. In other words, the form piece M has substantially a cylindrical form. Particularly for securing the coherence of the form piece, it is advantageous that the relation between the twisting of the bar-like blank and the determined cutting length is elected so that the twisting of the web material or the like on the first outer surface 10 of the form piece M is substantially at least one full twist from the first end to the second end of the form piece, i.e. between the second outer surfaces 20. As an embodiment, it can be mentioned that the web R consisting of one or several sheet materials can be treated, by spraying, spreading or in a corresponding manner, with a preferably small addition of an addi¬ tive, such as a glueing agent, impregnating agent, corrosion preventing agent, or an agent improving the electric properties of the web, etc. , before the pre¬ formation unit 2, to secure the cohesion and/or to provide further properties of the form piece. The glue can be preferably water-soluble.

Claims: Claims : 1. Form piece particularly for use as packing material, wherein the form piece comprises: a first outer surface (10) in the longitudinal direction of the form piece (M) , the sheet material or the like being wrinkled or arranged in a cor- responding manner on the same, second outer surfaces (20) joining the ends of the first outer surface (10) and extending in the cross-sectional direction of the form piece (M) , where the sheet material or the like forming the form piece (M) is randomly arranged in layers so that an air gap (IR) is provided between at least some sheet material layers or the like, characterized in that the first outer surface (10) forms a surface of a substantially cylindrical type, and that - the sheet material is twisted in random order inside the form piece (M) so that an air gap (IR) is provided between at least some sheet material layers or the like, for at least part of the length of the form piece (M) . 2. Form piece according to claim 1, characterized in that the surfaces (10, 20) of the form piece (M) , in the longitudinal direction on one hand and in the cross-sectional direction on the other hand, are essentially perpendicular to each other. 3. Form piece according to claim 1 or 2 , charac¬ terized in that the sheet material or the like of the form piece (M) is a cellulose-based material, such as paper, particularly recycled and/or waste paper. 4. Form piece according to any of claims 1—3, characterized in that the cross-sectional, second end faces of the form piece (M) are formed by cutting. 5. Method for manufacturing form pieces particularly for use as packing material, wherein a bar-like blank (3) is formed of a preferably con¬ tinuous web (R) , or the like, of a sheet material by reducing the width of the web (R) or the like substantially and by bringing the web material to the cross-sectional area of the bar-like blank (3) and the bar-like blank (3) is cut into form pieces (M) of determined length, characterized in that the bar-like blank (3) is twisted around its longi- tudinal axis before cutting it into form pieces (M) of determined length. 6. Method according to claim 5, characterized in that the web (R) or the like used is a cellulose- based material, such as paper, particularly recycled and/or waste paper. 7. Method acco iing to claim 5 or 6, characterized in that the bar-like blank (3) is formed by twisting the web (R) or the like or treating it in a correspond¬ ing manner for the purpose of producing a bar-like porous blank (3) with an air gap (IR) between adjacent sheet material layers wrinkled or produced by a cor- responding manner also after twisting and cutting into a certain length, particularly for achieving the flexibility properties of the form piece. 8. Method according to any of claims 5-7, charac¬ terized in that the relation between the twisting of the bar-like blank and the determined cutting length is elected so that the twisting of the web material or the like on the first outer surface (10) of the form piece (M) is substantially at least one full twist from the first end to the second end of the form piece (M) . 9. Apparatus for manufacturing form pieces for use particularly as packing material, wherein the apparatus comprises: means for uncoiling a web (R) or the like formed of a preferably continuous sheet material or the like, means (2) for reducing the width of the web (R) or the like and for making the web into a bar-like blank (3) containing air gaps, means (6) for cutting the bar-like blank (3) to a determined length for the purpose of producing said form pieces (M) for use as packing material, characterized in that the apparatus further com¬ prises: the means (4, 5) for twisting the bar-like blank (3) around the longitudinal axis of the bar-like blank (3) at least on the surface part of the bar¬ like blank (3) maintain at least part of the air gaps, wherein the means (4, 5) for twisting the bar-like blank (3) are placed before the means (6) for cutting the twisted bar-like blank (3) . 10. Use of a form piece, made of a sheet material, having a surface which is wrinkled or treated by a corresponding manner, at least the surface part being brought to a twisted form in the longitudinal direc¬ tion of the form piece (M) , and the cross-section containing air gaps, as a packing material or for a corresponding purpose.

Inventors: MATTILA TIMO, NORDLUNG KAI, MATTILA, TIMO, NORDLUNG, KAI
Applicants: DEVIPACK OY, MATTILA TIMO, NORDLUNG KAI, MATTILA, TIMO, NORDLUNG, KAI
Application year: 1994
Main classification: B31D5
IPC codes: B31C5, B31D5, B31F1, B65D81